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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 55 records · Page 3
All sourcesNASA NTRSDOE OSTI
NASA NTRSDate not supplied

Residual Strength of Hypervelocity Impacted Silica

Windows in the International Space Station are subjected to on-going micrometeoroid and orbital debris damage (MMOD). The reliability of the windows is being ensured by monitoring of damage, life prediction, and measurement of the residual strength of man-made and natural hypervelocity impact damage. The residual strength of man-made craters and MMOD craters harvested from space shuttle windows were used to estimate strength as a function of damage dimensions and thereby derive design allowables for U.S. and Russian fused silicas used in the ISS. US and Russian silica exhibit similar mechanical properties. An effect of impact angle is apparent, with 0o impacts exhibiting the lowest strength for Russian quartz-derived silica. The crater morphology for fused silica consists of a central pit, crush zone, shallow rings and radial cracks dividing petaloids. Morphology of alkaline glass is different from than that of fused silica, with a more distinct pit and pulverized region, and bell and tail-like features below the pit.

Silicia↗
NASA NTRSDate not supplied

Transfer function models for using empirical and physics-based simulation signal response data

In many situations, real or induced flaws such as tight cracks with known morphology cannot be manufactured in part geometry specimens or in real parts. Typically, surface fatigue cracks are manufactured in simple geometry specimens such as flat plates, dog-bone shaped flat or cylindrical specimens. If a nondestructive evaluation (NDE)technique is required to provide a reliably detectable flaw size, denoted asa90/95, for induced flaws in a part, then a direct method for qualifying the NDE procedure is to use appropriate induced flaw specimens and perform NDE procedure demonstration on the specimens. Probability of detection (POD)analysis of the empirical data may provide estimation of a90/95. This approach is described as direct POD demonstration testing, which may follow guidelines of MIL-HDBK-1823. This paper considers a case, where embedded tight cracklike induced flaws are to be detected reliably using a signal response based NDE procedure. Here, it is assumed that it is not practical to make surface or embedded induced flaw specimens in part geometry or configuration. Therefore, a direct POD demonstration testing cannot be undertaken. It is also assumed that simulation of signal response is possible for both surface and embedded induced flaws in part geometry specimens using a physics-based model. The proposed approach for NDE procedure qualification uses artificial flaws in simple geometry and part geometry specimens, and induced flaws in the same type of simple geometry specimens. Signal response data is taken on all sets of artificial and induced flaws in simple geometry and part geometry specimens. Moreover, simulated signal response data is generated for surface and embedded flaws. Thus, a case of five signal response versus flaw size datasets is considered. Three of the datasets are empirical and two datasets are physics model-based simulation datasets. A method of devising and using transfer function calculation dataset blocks to estimate the either the reliably detectable flaw size or the demonstration flaw size is provided.

Nondestructive evaluation↗
NASA NTRS2024

Residual Strength of Hypervelocity Impacted Silica

Windows in the International Space Station (ISS) are subject to ongoing micrometeoroid and orbital debris (MMOD) damage. The reliability of the windows is ensured by monitoring of damage, life prediction, and measurement of the residual strength of man-made and natural hypervelocity impacted window materials. Information on the residual strength of man-made craters and MMOD craters harvested from space shuttle windows was used to estimate strength as a function of damage dimensions and thereby derive design allowables for U.S. and Russian fused silicas used in the ISS. An effect of impact angle is apparent, with 0° impacts exhibiting the lowest strength for Russian quartz-derived silica. The crater morphology for fused silica consists of a central pit, crush zone, shallow rings, and radial cracks dividing shallow, petal-like lateral cracks (petaloids). The morphology of alkaline glass differs from that of fused silica, with a more distinct pit and pulverized region, and bell-shaped and tail-like features below the pit.

International space station,↗
DOE OSTI2020

Thermal Dehydration of Aluminum (Oxy)hydroxides on Fuel Cladding Material - 20200

The aluminum cladding of research-reactor fuel undergoes general corrosion with resulting formation of adherent aluminum (oxy)hydroxide films during in-reactor and post-discharge exposure to water under various conditions and temperatures. These (oxy)hydroxides contain chemically-bound water that poses challenges for extended dry storage due to the risk of thermal or radiolytic decomposition releasing free water and/or hydrogen and oxygen gases. This study comprised laboratory experiments of thermal drying behavior of aluminum (oxy)hydroxides to identify approaches for reducing bound water on fuel cladding prior to sealed dry storage. Effective drying strategies for adherent (oxy)hydroxides on fuel cladding will improve the safety of dry storage by mitigating potential avenues for additional corrosion and/or generation of flammable gases inside the storage canister. This work is part of a broader investigation to address knowledge gaps and technical data needs for dry storage of aluminum-clad spent nuclear fuel (ASNF), which included investigation of (oxy)hydroxide formation on aluminum alloy substrates immersed in water, characterization of service-grown films from ASNF, and radiolytic yield of hydrogen from (oxy)hydroxide powders and films. The current work comprises experimental thermal dehydration of aluminum trihydroxides (bayerite and gibbsite) characteristic of low-temperature (<80 deg. C) corrosion in water and aluminum oxyhydroxide (boehmite) characteristic of high temperature (>80 deg. C) corrosion in water. First, commercially produced (oxy)hydroxide powders (boehmite and gibbsite) were tested via thermogravimetric analysis (TGA) and differential scanning calorimetry (DSC). The effort aimed to identify or confirm key temperature ranges/thresholds for the thermal decomposition reactions, as well as impacts of ramp rate and hold times, for drying of isolated, high-surface-area (oxy)hydroxides. The information gleaned from powder tests was used to guide subsequent drying tests on adherent (oxy)hydroxide films grown on aluminum alloy substrates. TGA was used to analyze small samples of the aluminum coupons with adherent (oxy)hydroxide films. Specimens were characterized both pre- and post-drying using X-ray diffraction (XRD) to determine the film composition and scanning electron microscopy (SEM) to determine its morphology. Drying of adherent (oxy)hydroxide films was anticipated to pose additional complications relative to drying of (oxy)hydroxide powders. Anticipated challenges include achieving sufficient drying of the (oxy)hydroxide at low-enough temperature to avoid melting or other undesirable phase changes in the aluminum substrate and overcoming transport limitations of water through the thickness of a dense film or through a tortuous pore structure to reach the outer surface of the film. Inn addition, dehydration of (oxy)hydroxides significantly changes the film density, which may lead to substantial alterations in the morphology, including potential cracking and spalling of the film. TGA/DSC tests of gibbsite powders resulted in successful conversion to boehmite or alumina, depending on the maximum temperature reached. At low ramp rates (≤5 deg. C/min), the conversion to boehmite occurred around 300 deg. C (210-340 deg. C). XRD confirmed that boehmite was the only phase detected after tests reaching 450 deg. C. The transition to alumina occurred around 510 deg. C (470-550 deg. C), with XRD detecting only alumina after tests reaching at least 600 deg. C. Boehmite powders dehydrated to alumina at about 400 deg. C (330-460 deg. C) for coarse (77-μm particle diameter) powder and about 490 deg. C (420-520 deg. C) for fine (0.7-μm particle diameter) powder. For all powders tested, the maximum percent mass loss after drying to high temperature slightly exceeded the theoretical mass loss for complete dehydration of the stoichiometric (oxy)hydroxide to alumina, which is likely attributable to physisorbed water in the powder. Drying of a thick (∼8.6 μm), predominantly bayerite adherent film displayed a dramatic change in film morphology, with the initially continuous trihydroxide film cracking into sections on the order of 50 μm square and partially delaminating. The outermost layer of the film completely faked of in some regions. The layer exposed under the spalled oxide also displayed prominent cracking, with spacing on the order of 10 μm, but this surface layer appeared to remain completely adhered to the aluminum substrate. TGA showed mass losses per unit surface area up to ∼1.0 mg/cm{sup 2}. XRD characterization of the remaining oxide was inconclusive, with no crystalline phases detected. (authors)

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2023

Plasma surface ionization wave interactions with single channels

Abstract The study of plasma surface ionization waves (SIWs) in recent years has primarily focused on planar surfaces and periodic two dimensional structures. In application, substrates are likely to have non-planar morphology such as cracks, pores, and steps. Additionally, targets for the applications of medicine or catalysis may have targets with heterogeneous composition. This classification of targets are brought under the umbrella of complex interfaces. In this work, plasma SIWs were incident on a complex target consisting of a single channel cut into glass slides. The SIW velocities for the in-channel portion of the wave and radially propagating portion of the wave were tracked. It was found that surface wave velocities are not significantly affected by channel geometry, but primarily increase with pulse energy. A third propagation direction for the SIW is characterized in the azimuthal direction relative to the radial portion of the wave. Channel geometry is found to greatly effect the area treated by the plasma but not the propagation velocity of the surface wave. Surface wave morphology and the impact on application is also discussed. A simple model was introduced to understand the mechanisms behind SIW escape from a channel. It was found that the ratio of pulse energy to a geometry dependent minimum energy can predict the escape angle of a SIW from single channels.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2023

Variations in Creep Performance of P92 Steel Within Its Composition Range: Influence of N Solubility

Underspecified composition ranges often lead to alloys with unpredictable mechanical performance. To better understand the changes in microstructure and mechanical performance associated with variations of key elements, three versions of P92 are formulated within, or close to, the specified allowable for N, B, and C ranges. Chromium and Si are also varied to influence N solubility. Different service conditions (i.e., temperature and stress) are explored. It is observed that >80% decrease in creep life occurs at 625 °C and 155 MPa for the highest B and N containing alloy. Multiscale characterization reveals key changes due to the trace element variation. The high B and N containing alloy forms deleterious BN precipitates with morphology that promotes crack nucleation and damage accumulation, but this alloy additionally forms higher fractions of beneficial MX precipitates. The alloy with the lowest B and N concentrations but greater C content shows the best creep performance—a consequence of the refined M 23 C 6 carbide precipitate population and the absence of large-scale inclusions or BN precipitates. Calculations of creep activation energy reveal that the high B and N containing alloy is more prone to damage accumulation which causes an early onset of accelerating creep and greater minimum creep rate.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Corrosion of Commercial Mg–Al Alloys: AZ31B, AM60, and AZ91D

Aqueous corrosion, atmospheric corrosion, and ionic liquid dissolution studies were performed on commercial alloys AZ31B, AM60, and AZ91D and compared with previously reported results for single-phase binary Mg–Al alloys containing similar Al concentrations (αMg-2 at% Al, αMg-5 at% Al, and Mg-8 at% Al). Polarization studies in 0.6 M NaCl were used to characterize the aqueous free corrosion behavior during 20-h free immersion. Accelerated corrosion testing was performed using a rotating-disk electrode which revealed the evolution of an Al-rich mud-cracking and platelet morphology. Atmospheric droplet testing showed rapid pH increases that depended on the Al concentration in the alloy. Time-dependent contact angle measurements showed that the degree of droplet wetting increased during free corrosion by ~50° over 20 h in 0.6 M NaCl. Ionic liquid dissolution studies in 1:2 M choline chloride:urea deep eutectic solvent were performed in order to examine the current-voltage behavior of these alloys in the absence of water and hydrogen reduction. The results of these studies revealed the formation of nanowire corrosion morphologies within a honeycomb lattice structure which we attribute to selective dissolution of Mg via a two-dimensional stepflow process

25 ENERGY STORAGE↗
NASA NTRS1981

The fracture morphology of nickel-base superalloys tested in fatigue and creep-fatigue at 650 C

The fracture surfaces of compact tension specimens from seven nickel-base superalloys fatigue tested at 650 C were studied by scanning electron microscopy and optical metallography to determine the nature and morphology of the crack surface in the region of stable growth. Crack propagation testing was performed as part of an earlier study at 650 C in air using a 0.33 Hz fatigue cycle and a creep-fatigue cycle incorporating a 900 second dwell at maximum load. In fatigue, alloys with a grain size greater than 20 micrometers, HIP Astroloy, Waspaloy, and MERL 76, exhibited transgranular fracture. MERL 76 also displayed numerous fracture sites which were associated with boundaries of prior powder particles. The two high strength, fine grain alloys, IN 100 and NASA IIB-7, exhibited intergranular fracture. Rene 95 and HIP plus forged Astroloy displayed a mixed failure mode that was transgranular in the coarse grains and intergranular in the fine grains. Under creep-fatigue conditions, fracture was found to be predominantly intergranular in all seven alloys.

Gayda, J.↗
NASA NTRS1975

A film-rupture model of hydrogen-induced, slow crack growth in alpha-beta titanium

The appearance of the terrace like fracture morphology of gaseous hydrogen induced crack growth in acicular alpha-beta titanium alloys is discussed as a function of specimen configuration, magnitude of applied stress intensity, test temperature, and hydrogen pressure. Although the overall appearance of the terrace structure remained essentially unchanged, a distinguishable variation is found in the size of the individual terrace steps, and step size is found to be inversely dependent upon the rate of hydrogen induced slow crack growth. Additionally, this inverse relationship is independent of all the variables investigated. These observations are quantitatively discussed in terms of the formation and growth of a thin hydride film along the alpha-beta boundaries and a qualitative model for hydrogen induced slow crack growth is presented, based on the film-rupture model of stress corrosion cracking.

Nelson, H. G.↗
DOE OSTI2022

Nanotomographic observation and statistical analysis of overcharging induced cracks in LiCoO 2 single crystalline particles

Particle fracture represents an important mode of battery electrode degradation. Extensive cracking occurs in the layered oxide cathodes of lithium-ion rechargeable batteries when they are charged beyond safe operational voltages. In this paper, we analyze the morphology and distribution of cracks in over 100 overcharged LiCoO 2 (LCO) single-crystalline particles imaged via X-ray nanotomography. Herein, we observe a strong particle size dependence in both nucleation and growth of cracks, with percentage of cracked particles, crack size, and crack surface area per unit volume all increasing significantly with particle volume. Increasing the cutoff voltage above 4.6V is found to trigger much more pronounced crack growth, which we attribute to the large misfit stress caused by the H1-3 to O1 phase transition. This study offers valuable statistical insights into the fracture behavior of layered oxide cathodes and reveals the importance of particle size control on electromechanical degradation of battery electrodes.

25 ENERGY STORAGE↗
NASA NTRS2015

Analyses of Hubble Space Telescope Aluminized-Teflon Multilayer Insulation Blankets Retrieved After 19 Years of Space Exposure

Since its launch in April 1990, the Hubble Space Telescope (HST) has made many important observations from its vantage point in low Earth orbit (LEO). However, as seen during five servicing missions, the outer layer of multilayer insulation (MLI) has become increasingly embrittled and has cracked in many areas. In May 2009, during the 5th servicing mission (called SM4), two MLI blankets were replaced with new insulation and the space-exposed MLI blankets were retrieved for degradation analyses by teams at NASA Glenn Research Center (GRC) and NASA Goddard Space Flight Center (GSFC). The retrieved MLI blankets were from Equipment Bay 8, which received direct sunlight, and Equipment Bay 5, which received grazing sunlight. Each blanket was divided into several regions based on environmental exposure and/or physical appearance. The aluminized-Teflon (DuPont, Wilmington, DE) fluorinated ethylene propylene (Al-FEP) outer layers of the retrieved MLI blankets have been analyzed for changes in optical, physical, and mechanical properties, along with chemical and morphological changes. Pristine and as-retrieved samples (materials) were heat treated to help understand degradation mechanisms. When compared to pristine material, the analyses have shown how the Al-FEP was severely affected by the space environment. Most notably, the Al-FEP was highly embrittled, fracturing like glass at strains of 1 to 8 percent. Across all measured properties, more significant degradation was observed for Bay 8 material as compared to Bay 5 material. This paper reviews the tensile and bend-test properties, density, thickness, solar absorptance, thermal emittance, x-ray photoelectron spectroscopy (XPS) and energy dispersive spectroscopy (EDS) elemental composition measurements, surface and crack morphologies, and atomic oxygen erosion yields of the Al-FEP outer layer of the retrieved HST blankets after 19 years of space exposure.

Radiation↗
DOE OSTI2025

Irradiation Testing of Ultrasonic Transducers

Ultrasonic technologies offer the potential for high accuracy and resolution in-pile measurement of numerous parameters, including geometry changes, temperature, crack initiation and growth, gas pressure and composition, and microstructural changes. Many Department of Energy-Office of Nuclear Energy (DOE-NE) programs are exploring the use of ultrasonic technologies to provide enhanced sensors for in-pile instrumentation during irradiation testing. For example, the ability of single, small diameter ultrasonic thermometers (UTs) to provide a temperature profile in candidate metallic and oxide fuel would provide much needed data for validating new fuel performance models. Other efforts include an ultrasonic technique to detect morphology changes (such as crack initiation and growth) and acoustic techniques to evaluate fission gas composition and pressure. These efforts are limited by the lack of existing knowledge of ultrasonic transducer material survivability under irradiation conditions. To address this need, the Pennsylvania State University (PSU) was awarded an Advanced Test Reactor National Scientific User Facility (ATR NSUF) project to evaluate promising magnetostrictive and piezoelectric transducer performance in the Massachusetts Institute of Technology Research Reactor (MITR) up to a fast fluence of at least 1021 n/cm2 (E> 0.1 MeV). This test will be an instrumented lead test; and real-time transducer performance data will be collected along with temperature and neutron and gamma flux data. By characterizing magnetostrictive and piezoelectric transducer survivability during irradiation, test results will enable the development of novel radiation tolerant ultrasonic sensors for use in Material and Test Reactors (MTRs). The current work bridges the gap between proven out-of-pile ultrasonic techniques and in-pile deployment of ultrasonic sensors by acquiring the data necessary to demonstrate the performance of ultrasonic transducers

Daw, J.↗
DOE OSTI2024

The influence of electrode crack dimensions on the durability of polymer electrolyte membrane fuel cells

Electrode cracks in polymer electrolyte membrane fuel cells (PEMFCs) are correlated with early onset failures. Here, in this work we investigate the influence of cracked gas diffusion electrodes (GDEs) on the durability of the membrane electrode assembly (MEA) using a combined chemical-mechanical accelerated stress test (AST). Electrode crack dimensions were systematically tuned using ink formulations and material selection strategies. A parameter to describe the crack width areal density (Φ CW ) was used to quantify the degree of discontinuity in the electrode surfaces. Open circuit voltage (OCV) transient analyses were used to benchmark and characterize the failure mechanisms in the MEAs as a function of the Φ CW . While smaller electrode-level cracks, on the order of microns, yielded a 28 % decrease in operating lifetime, larger cracks that propagated from a discontinuous, microporous layer (MPL) coating, decreased the operating lifetime by 56 %. This work emphasizes the need for material processing strategies that consider defect tolerances to limit membrane failures in PEMFCs.

08 HYDROGEN↗
DOE OSTI2022

A phase-field model of quasi-brittle fracture for pressurized cracks: Application to UO 2 high-burnup microstructure fragmentation

Here, in this paper, we present a phase-field model of quasi-brittle fracture with pressurized cracks, with dedicated applications for polycrystalline materials. The model is formulated as a minimization problem within the variational framework. The external work done by pressure on the crack surfaces is included in the objective function. Several careful modeling choices lead to a regularization-length-independent critical strength. The model is constructed to give a softening response with an underlying linear traction-separation law. The pressure-dependent softening response and the regularization of the prescribed pressure are demonstrated with a (quasi) one-dimensional numerical analysis. In a two-dimensional numerical analysis under plane strain assumptions, the critical stress corresponding to crack propagation (as predicted by our quasi-brittle fracture model) is compared with linear elastic fracture mechanics (LEFM) analytical solutions. Our model is further utilized to simulate fission-gas-induced fragmentation of the UO 2 high-burnup structure (HBS). Simulation results show that pressurized bubbles can cause crack nucleation and propagation, and that the bubble size and the surrounding external pressure affect the critical pressure corresponding to crack nucleation. Simulations of a partial HBS at different recrystallization stages show that different grain structures (due to recrystallization) also influence crack paths and fragmentation morphology.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Toward a Theory of the Evolution of Drop Morphology and Splintering by Freezing

Abstract The drop freezing process is described by a phase-field model. Two cases are considered: when the freezing is triggered by central nucleation and when nucleation occurs on the drop surface. Depending on the environmental temperature and drop size, different morphological structures develop. Detailed dendritic growth was simulated at the first stage of drop freezing. Independent of the nucleation location, a decrease in temperature within the range from ~−5° to −25°C led to an increase in the number of dendrites and a decrease in their width and the interdendritic space. At temperatures lower than about −25°C, a planar front developed following surface nucleation, while dendrites formed a granular-like structure with small interdendritic distances following bulk nucleation. An ice shell grew in at the same time (but slower) as dendrites following surface nucleation, while it started forming once the dendrites have reached the drop surface in the case of central nucleation. The formed ice morphology at the first freezing stage predefined the splintering probability. We assume that stresses needed to break the ice shell arose from freezing of the water in the interdendritic spaces. Under this assumption, the number of possible splinters/fragments was proportional to the number of dendrites, and the maximum rate of splintering/fragmentation occurred within a temperature range of about −10° to −20°C, is in agreement with available laboratory and in situ measurements. At temperatures < −25°C, freezing did not lead to the formation of significant stresses, making splintering unlikely. The number of dendrites increased with drop size, causing a corresponding increase in the number of splinters. Examples of morphology that favors drop cracking are presented, and the duration of the freezing stages is evaluated. Sensitivity of the freezing process to the surface fluxes is discussed.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2022

Exploring the Impact of N Solubility and Trace Elements on the Creep Properties of P92 Steel

Trace elements can have major consequences on the properties of creep resistant martensitic steels. To better understand the changes in microstructure and mechanical performance associated with the variation of trace elements and enable design of steels operating at more demanding conditions, we formulated three versions of P92 within the specified allowable N, B, C and Si ranges. Different service conditions were explored, and >80% decrease in creep life was observed at 625°C 155MPa for the highest B and N containing alloy. Multiscale characterization (OM, SEM, TEM) revealed key changes due to the trace element variation. The high trace content alloy formed deleterious BN precipitates with morphology that would promote crack nucleation, but also formed higher fractions of beneficial MX precipitates. The alloy with the lowest trace content showed the best creep performance – a result of the refined precipitate populations and the absence of large-scale inclusions and BN precipitates.

Antonov, Stoichko↗